Fluid loss control completion system and methodology

Abstract

A technique provides a simplified and cost-effective approach for deployment and operation of completion systems. The construction of the overall completion system and the deployment methodology provide an efficient approach for placement and operation of completion systems in a variety of wellbores. In many applications, the system and methodology may be used for sand control applications in which the completion equipment comprises sand control features, such as sand screens deployed along well zones.

What is claimed is: 
     
       1. A method for use in a well, comprising:
 conveying a first completion downhole into a wellbore, the first completion having a mechanical formation isolation valve and a plurality of sand control assemblies; 
 positioning the sand control assemblies to receive well fluid from a plurality of corresponding well zones and a surrounding formation; 
 deploying a second completion downhole into the wellbore, the second completion comprising a shifting tool, a plurality of flow control valves, a fluid loss control device, a production packer located uphole of the fluid loss control device, and a production tubing; 
 sealing the fluid loss control device against a surrounding well casing downhole of the production packer via a seal system; 
 using a one-way flow device in the fluid loss control device to enable fluid flow along an annulus surrounding the second completion in an uphole direction while blocking fluid flow in a downhole direction; and 
 shifting the mechanical formation isolation valve with the shifting tool as the second completion is moved into engagement with the first completion. 
 
     
     
       2. The method as recited in  claim 1 , wherein conveying comprises conveying the first completion downhole in a single trip. 
     
     
       3. The method as recited in  claim 2 , wherein deploying comprises deploying the second completion downhole in a single trip. 
     
     
       4. The method as recited in  claim 1 , wherein conveying comprises conveying the first completion downhole as a lower completion and an intermediate completion in two trips. 
     
     
       5. The method as recited in  claim 4 , wherein deploying comprises deploying the second completion downhole in a single trip. 
     
     
       6. The method as recited in  claim 1 , further comprising taking fluid flows through an interior of the production tubing by opening at least one of the flow control valves during movement of the second completion downhole into engagement with the first completion. 
     
     
       7. The method as recited in  claim 1 , further comprising placing at least one rupture disc in the fluid loss control device. 
     
     
       8. The method as recited in  claim 1 , further comprising flowing a fluid from the production tubing, out through a lower zone flow control valve of the plurality of flow control valves, up through the fluid loss control device, and past the production packer prior to fully engaging the second completion with the first completion. 
     
     
       9. A method, comprising:
 locating a first completion in a wellbore; 
 deploying a second completion downhole toward the first completion, wherein deploying comprises deploying the second completion with a production packer and a fluid loss control device which forms a seal with a surrounding casing downhole of the production packer; 
 placing a check valve in the fluid loss control device to enable fluid flow along an annulus surrounding the second completion in an uphole direction while blocking fluid flow in a downhole direction; 
 using a shifting tool on the second completion to open a mechanical flow isolation valve on the first completion to provide a fluid communication path between a surrounding formation and the second completion; and 
 sealably engaging the second completion with the first completion via a polished bore receptacle. 
 
     
     
       10. The method as recited in  claim 9 , further comprising moving fluid out into the formation after opening the mechanical flow isolation valve. 
     
     
       11. The method as recited in  claim 9 , further comprising taking fluid returns up through the second completion via an open flow control valve in the second completion after opening the mechanical flow isolation valve in the first completion. 
     
     
       12. The method as recited in  claim 9 , wherein locating comprises locating the first completion in two trips downhole to deploy a lower completion and an intermediate completion. 
     
     
       13. A system for use in a well, comprising:
 a first completion having an open hole isolation packer, a plurality of sand control assemblies, a mechanical flow isolation valve, and a polished bore receptacle; and 
 a second completion having:
 a shifting tool to open the mechanical flow isolation valve during engagement of the second completion with the first completion; 
 a seal assembly positioned to sealably engage the polished bore receptacle; 
 a plurality of flow control valves corresponding with a plurality of well zones; 
 a production tubing in fluid communication with the plurality of flow control valves; 
 a production packer mounted on the production tubing; 
 a fluid loss control device having a seal system oriented to seal against a surrounding well casing intermediate the production packer and the plurality of flow control valves; and 
 an on/off flow control valve selectively actuatable to control fluid flow between an interior of the second completion and a surrounding annulus, the on/off flow control valve and the fluid loss control device cooperating to selectively block or enable flow along the surrounding annulus prior to setting of the production packer. 
 
 
     
     
       14. The system as recited in  claim 13 , wherein the first completion comprises a lower completion and an intermediate completion.